Custom Cardboard Blank Layout Optimization for Fold Avoidance
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Solution Overview
Problem
The challenge in packaging varying shipment sets with different sizes and quantities is exacerbated by unwanted transverse folds in fanfold cardboard, which can lead to incorrect folding, machine jams, and instability in packaging, often resulting in waste and inefficiencies in automated systems.
Innovation Solution
A method and system that calculate and optimize blank layouts for custom-sized cardboard boxes by determining the minimum distance required between transverse folds and crease lines, using sensors to detect fold positions, and adjusting cutting and creasing processes to minimize waste and ensure stable folding, allowing for the creation of blanks with reduced unwanted folds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fanfold cardboard is used to create custom-sized blanks, then material availability and ease of handling are improved, but unwanted transverse folds are introduced that cause incorrect folding and packaging instability
Solution Approach 1:
The system performs preliminary detection of transverse fold positions in the fanfold cardboard before cutting the blank. Based on this detection, the blank layout is pre-adjusted to ensure crease lines are positioned at a safe distance from detected folds, preventing folding errors before they occur during the packaging process
Solution Approach 2:
The system uses sensors to detect the actual position of transverse folds in the fanfold cardboard and feeds this information back to the control unit. The control unit then adjusts the blank layout and cutting positions accordingly, creating a closed-loop control system that adapts to material variations and ensures reliable packaging
2Quantity of substance
If transverse folds are present close to crease lines in cardboard blanks, then material utilization is improved, but folding accuracy deteriorates leading to machine jams and packaging defects
Solution Approach 1:
The system calculates and determines the minimum safe distance between transverse folds and crease lines before cutting the blank. The blank layout is pre-adjusted to maintain this safety margin, ensuring that even when material is tightly packed, folds will not interfere with the crease lines during folding operations
Solution Approach 2:
The system dynamically adjusts the blank layout and cutting positions based on the detected positions of transverse folds. When folds are detected close to where crease lines would normally be positioned, the system shifts the layout to maintain adequate spacing, optimizing both material utilization and folding accuracy in real-time
3Productivity
If custom-sized blanks are created without fold detection, then production speed is maintained, but waste material increases due to incorrect folding and packaging failures
Solution Approach 1:
The system performs rapid detection of transverse fold positions and calculates the optimized blank layout before cutting begins. This preliminary planning ensures that the first cut is correct, avoiding the need for rework or disposal of defective blanks, thus reducing waste while maintaining production speed
Solution Approach 2:
The system replaces manual inspection and adjustment of cardboard blanks with an automated sensor-based detection and control system. The sensors quickly locate transverse folds and the control unit automatically adjusts cutting positions, eliminating the time-consuming manual processes while reducing material waste through precise, error-free blank creation
Data Source
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AI summary
A System (60) for creating custom-sized cardboard blanks for folding packagings comprises a first and at least a second supply for fanfold cardboard (64, 66), a central control unit adapted for calculating, based on order information regarding the desired minimum dimensions of a current packaging, under predefined optimization criteria a first blank layout for folding the packaging, said blank layout comprising a leading edge and an ending edge and transverse and longitudinal crease lines dividing the blank having a desired length and width into panels, defining, based on predefined criteria, areas around the transverse crease lines and the leading and ending edges, in which no transverse folds (80, 82) from fanfolding the cardboard (64, 66) should be present, sensors communicatively coupled with said control unit for obtaining information on the presence of transverse folds (80) in cardboard ready to be cut-off from the first web, sensors communicatively coupled with said control unit for obtaining information on the presence of transverse folds (82) in cardboard ready to be cut-off from the second web, structure (62) for cutting-off the piece of cardboard from the first or the second web and forming the desired blank, said central control unit further adapted for checking, if a transverse fold would be present in at least one of said areas if the piece of cardboard would be cut-off from the first web and performing, in case such transverse fold would be present, at least one of the following steps: A) calculating a second blank layout for folding the same packaging, said second layout comprising transverse and longitudinal crease lines at different positions than the first layout, B) enlarging at least one of the panels by shifting a respective transverse crease line and the ending edge, C) checking, if a transverse fold would be present in at least one of said areas if the piece of cardboard would be cut-off from the second web, and, if no transverse folds are present in said areas, cutting-off the piece of cardboard from the second web.